Conductive Rubber Sensor Interconnect for Insulin Pump Occlusion Detection

The patent introduces conductive rubber elements as intermediary components between the force sensor contact tabs and the circuit board conductive leads. These rubber elements serve as flexible electrical connectors that eliminate the need for soldering or adhesives, thereby reducing manufacturing complexity while maintaining reliable electrical connections. The conductive rubber acts as a mediator that bridges the mechanical and electrical interfaces without requiring complex thermal or chemical bonding processes.

The patent employs flexible circuit boards with conductive leads and conductive rubber elements that can be bent and shaped to fit within compact pump housings. The flexible nature of these components allows them to adapt to limited space while maintaining electrical connectivity. This flexibility enables sensor integration in small form factors without requiring complex rigid wiring harnesses or large assembly spaces.

The patent replaces the thermal bonding process of soldering with a mechanical compression system using conductive rubber elements. The electrical connections are established through mechanical pressure that forces conductive pathways through the rubber material, eliminating exposure to high temperatures. This mechanical substitution maintains connection strength through compression force while avoiding the harmful thermal effects that could damage sensitive sensor components or surrounding electronics.